Machining status monitoring method and machining status monitoring apparatus

ABSTRACT

A machining status monitoring apparatus is provided on a machine tool, and has a plurality of actual CCD cameras for imaging the tool and workpiece from different view points and generating actual two-dimensional image data thereof, a virtual image generating section having a plurality of virtual CCD cameras corresponding to the actual CCD cameras, in which the tool and workpiece of three-dimensional model are imaged by the virtual CCD cameras from each point and virtual two-dimensional image data thereof are generated, and a display control section for selecting one virtual CCD camera corresponding to the virtual two-dimensional image data in which the distal end of the tool is not hidden by the workpiece among the generated two-dimensional image data, and displaying the actual two-dimensional image data generated by the actual CCD camera corresponding to the selected virtual CCD camera on a display device.

TECHNICAL FIELD

The present invention relates to a machining status monitoring method and machining status monitoring apparatus where monitoring images of the machining status of a workpiece in a machine tool are displayed on a display device.

BACKGROUND ART

Many machine tools are configured so that workpieces are machined in an internal area closed by a cover, thereby securing the security. Although the cover has a window, an operator can visually recognize only a limited portion through this window, and therefore, there is a limitation in monitoring the machining status of a workpiece.

Therefore, as described in the Japanese Unexamined Patent Application Publication No. 2005-190102, for example, a camera is arranged in the internal area in the machine tool and images obtained from this camera are displayed on the display device, thereby the operator can check the machining status of a workpiece with the displayed images.

SUMMARY OF INVENTION Technical Problem

However, even if a camera is arranged as described above, it is possible that only images in which the tool is hidden by the workpiece are obtained due to the position relationship between the tool and the workpiece. Therefore, there is a case where the machining status of a workpiece cannot be monitored sufficiently.

The present invention has been achieved in view of the above-described circumstances and an object of the invention is to provide a machining status monitoring method and machining status monitoring apparatus with which it is possible to sufficiently monitor the machining status of a workpiece with images obtained from imaging means.

Solution to Problem

The present invention, for achieving the above-described object, relates to a machining status monitoring method for, in a machine tool in which one or both of tool holding means for holding a tool and workpiece holding means for holding a workpiece are operated based on operation commands, monitoring the machining status with actual two-dimensional image data displayed on display means, the actual two-dimensional image data generated by at least one of a plurality of actual imaging means, disposed in the machine tool, for imaging the tool and workpiece, or the tool, workpiece and workpiece holding means at a certain time interval from different view points, and in turn generating actual two-dimensional image data thereof, wherein

based on the operation commands and data on three-dimensional models of the holding means, tool and workpiece, model data of the holding means, tool and workpiece when one or both of the holding means are operated according to the operation commands are generated and the model data thereof are updated,

simultaneously virtual two-dimensional image data of the tool and workpiece, or virtual two-dimensional image data of the tool, workpiece and workpiece holding means, the virtual two-dimensional image data which is assumed to be obtained when a three-dimensional space is virtually set; in this virtual three-dimensional space, the three-dimensional models of the tool and workpiece, or the three-dimensional models of the tool, workpiece and workpiece holding means, are arranged and imaging means having the same condition as that of the actual imaging means are virtually set and arranged as many as the actual imagining means; and the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the virtual imaging means from the same view points as those of the actual imaging means, are in turn generated based on the updated model data, and

based on the generated virtual two-dimensional image data, at least one is selected from the virtual imaging means corresponding to, among a plurality of the virtual two-dimensional images, the virtual two-dimensional images in which the distal end of the tool is not hidden by the workpiece or the workpiece holding means, and the actual two-dimensional image data generated by the actual imaging means corresponding to the selected virtual imaging means is displayed on the display means.

This machining status monitoring method is appropriately carried out by the following machining status monitoring apparatus.

That is, the machining status monitoring apparatus is provided on a machine tool having tool holding means for holding a tool, workpiece holding means for holding a workpiece, drive means for operating one or both of the holding means, control means for controlling the operation of the drive means based on the operation commands relating to one or both of the holding means, and display means for displaying image data, and comprises:

a plurality of actual imaging means for imaging the tool and workpiece, or the tool, workpiece and workpiece holding means at a certain time interval from different view points, and in turn generating actual two-dimensional image data thereof;

model data updating means for, after receiving an operation command from the control means, based on the received operation command and data on three-dimensional models of the holding means, tool and workpiece, generating model data of the holding means, tool and workpiece which are in a state in which one or both of the holding means were operated according to the operation command, and updating the model data thereof;

virtual image generating means for generating virtual two-dimensional image data of the tool and workpiece, or virtual two-dimensional image data of the tool, workpiece and workpiece holding means, based on the model data updated by the model data updating means, the virtual image generating means in which virtual two-dimensional image data which are assumed to be obtained when a three-dimensional space is virtually set; in this virtual three-dimensional space, the three-dimensional models of the tool and workpiece, or the three-dimensional models of the tool, workpiece and workpiece holding means, are arranged and imaging means having the same condition as that of the actual imaging means are virtually set and arranged as many as the actual imagining means; and the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the virtual imaging means from the same view points as those of the actual imaging means, are generated in turn; and

display control means for, based on the virtual two-dimensional image data generated by the virtual image generating means, selecting at least one from the virtual imaging means corresponding to, among a plurality of the virtual two-dimensional images, the virtual two-dimensional images in which the distal end of the tool is not hidden by the workpiece or the workpiece holding means and displaying the actual two-dimensional image data generated by the actual imaging means corresponding to the selected virtual imaging means on the display means.

According to this machining status monitoring apparatus, when the drive means is controlled by the control means based on an operation command relating to one or both of the tool holding means and workpiece holding means, and thereby one or both of the holding means are operated, the model data of the holding means, tool and workpiece are updated simultaneously with the actual operations of the holding means.

Specifically, based on the operation command from the control means and the model data of the workpiece holding means, tool and workpiece, the model data updating means generates model data of the holding means, tool and workpiece which are in a state in which one or both of the holding means are operated according the operation command, and updates the model data thereof.

While the holding means are being operated, the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the plurality of actual imaging means from different view points and actual two-dimensional image data thereof are generated in turn. On the other hand, virtual two-dimensional image data of the tool and workpiece, or virtual two-dimensional image data of the tool, workpiece and workpiece holding means, are generated in turn by the virtual image generating means based on the model data updated by the model data updating means. These virtual two-dimensional image data are image data which are assumed to be obtained as follows: a three-dimensional space is virtually set; in this virtual three-dimensional space, the three-dimensional models of the tool and workpiece, or the three-dimensional models of the tool, workpiece and workpiece holding means are arranged and imaging means having the same condition as that of the actual imaging means (for example, having the same intrinsic parameters) are virtually set and arranged as many as the actual imaging means; and then the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the virtual imaging means from the same view points as those of the actual imaging means.

It is sufficient that the actual two-dimensional images and the virtual two-dimensional images each show at least the tool and workpiece, or at least the tool, workpiece and workpiece holding means. The tool holding means and other machine tool components may be contained in the images in addition to them. It is noted that the workpiece holding means refers to a table, jig or the like when the machine tool is a machining center, and refers to a spindle, chuck or the like when the machine tool is a lathe, for example.

Thereafter, based on the virtual two-dimensional image data generated by the virtual image generating means, the display control means selects at least one from the virtual imaging means corresponding to, among the virtual two-dimensional images, the virtual two-dimensional images in which the distal end of the tool is not hidden by the workpiece or the workpiece holding means, and displays on the display means the actual two-dimensional image data generated by the actual imaging means corresponding to the selected virtual imaging means.

In the virtual two-dimensional images, the determination whether the distal end of the tool is hidden by the workpiece or the workpiece holding means can be made by referring to depth information in the Z-buffer in the virtual three-dimensional space, for example. When there is a plurality of the virtual imaging means capturing the virtual two-dimensional image in which the distal end of the tool is not hidden, all of the actual two-dimensional image data generated by the actual imaging means corresponding to such virtual imaging means may be displayed. Alternatively, only the actual two-dimensional image data generated by some of the actual imaging means corresponding to such virtual imaging means (for example, determined at random) may be displayed.

Thus, according to the machining status monitoring method and machining status monitoring apparatus of the present invention, it is configured so that, based on the virtual two-dimensional image data generated by imaging the tool and workpiece, or the tool, workpiece and workpiece holding means from different view points by means of a plurality of the virtual imaging means, at least one is selected from the virtual imaging means which generated the virtual two-dimensional image data in which the distal end of the tool is not hidden and the actual two-dimensional image data generated by the actual two-dimensional imaging means corresponding to the selected virtual imaging means is displayed on the display means. Therefore, actual images in which the distal end of the tool is not hidden can be always displayed. Thereby, the operator can always visually recognize the machining status of a workpiece through the displayed images, wherein it is possible to sufficiently monitor the machining status.

It may be configured so that the machining status monitoring apparatus has a sectional image generating means for, based on the model data updated by the model data updating means, generating sectional image data including the tool and a sectional shape appearing when at least the workpiece is cut along a plane passing through the distal end of the tool and the display control means checks, based on the virtual two-dimensional image data generated by the virtual image generating means, whether the distal end of the tool is hidden by the workpiece in all of the virtual two-dimensional images, and displays on the display means the sectional image data generated by the sectional image generating means when determining that the distal end of the tool is hidden in all of the virtual two-dimensional images.

In the case of hole machining or groove machining, the distal end of the tool is hidden by the workpiece. Therefore, even if a plurality of the actual imaging means is provided, the distal end of the tool is hidden by the workpiece in all of the actual two-dimensional image data generated by the actual imaging means. In this case, the operator cannot monitor the machining status of a workpiece through the images displayed on the display means.

Therefore, as described above, when it is configured so that sectional image data is displayed on the display means in the case where the distal end of the tool is hidden in all of the virtual two-dimensional images, the operator can check the machining status of a workpiece.

The sectional image generating means may be configured to set a plane which passes through the distal end of the tool and is perpendicular to the optical axis of any one of the actual imaging means as a cutting plane in generating sectional image data.

When configured in this way, since a sectional image when the tool and the workpiece are viewed from the same direction as that of any one of the actual imaging means can be displayed, it is possible to prevent the operator from having the difficulty of recognizing the direction from which the tool and workpiece are viewed because the direction is changed when a sectional image is displayed. In this sense, it is preferred that the cutting plane is perpendicular to the optical axis of the actual imaging means which generated the actual two-dimensional image data that has been displayed just before the sectional image data is displayed (when switching from the actual image data to the sectional image data).

In the case where the machine tool is a lathe and the workpiece holding means is a spindle, the sectional image generating means may be configured to set a plane passing through the distal end of the tool and the axis of the spindle as a cutting plane in generating sectional image data.

EFFECT OF THE INVENTION

Thus, according to the machining status monitoring method and machining status monitoring apparatus of the present invention, among the image data obtained from the actual imaging means, the image data in which the distal end of the tool is not hidden can be always displayed. Therefore, the operator can sufficiently monitor the machining status of a workpiece.

BRIEF DESCRIPTION OF DRAWINGS

FIG. 1 is a block diagram showing a schematic configuration of a machining status monitoring apparatus and other components according to one embodiment of the present invention.

FIG. 2 is a perspective view showing a schematic configuration of a machine tool provided with the machining status monitoring apparatus of the embodiment.

FIG. 3 is a plane view showing an arrangement relationship between a plurality of actual CCD cameras arranged on the machine tool.

FIG. 4 is an illustration showing examples of an actual image of the embodiment.

FIG. 5 is a flowchart showing a series of processes in a model data updating section of the embodiment.

FIG. 6 is a flowchart showing a series of processes in a virtual image generating section of the embodiment.

FIG. 7 is an illustration showing examples of a virtual image of the embodiment.

FIG. 8 is a flowchart showing a series of processes in a camera selection section of the embodiment.

FIG. 9 is a flowchart showing a series of processes in a display-image switching section of the embodiment.

FIG. 10 is a perspective view showing the tool and workpiece at the time of groove machining.

FIG. 11 is an illustration showing examples of a sectional image of the embodiment.

FIG. 12 is an illustration showing an example of a sectional image of another embodiment of the present invention.

DESCRIPTION OF EMBODIMENT

Hereinafter, a specific embodiment of the present invention will be described with reference to the accompanying drawings. FIG. 1 is a block diagram showing a schematic configuration of a machining status monitoring apparatus and other components according to one embodiment of the present invention, and FIG. 2 is a perspective view showing a schematic configuration of a machine tool provided with the machining status monitoring apparatus of the embodiment. And FIG. 3 is a plane view showing an arrangement relationship between a plurality of actual CCD cameras arranged on the machine tool.

As shown in FIG. 1, a machining status monitoring apparatus 1 of the present embodiment has a plurality of actual CCD cameras (4 cameras in the present embodiment) 11, 12, 13 and 14, a camera parameter storage section 15, a model data storage section 16, a model data updating section 17, a virtual image generating section 18, a display control section 23, and a sectional image generating section 26, and is provided on a machine tool 50 called a machining center as shown in FIG. 2, for example.

Here, first of all, the machine tool 50 is explained. As shown in FIGS. 1 and 2, the machine tool 50 includes: a bed 51; a fist saddle 52 which is disposed on the bed 51 and which can move freely in a horizontal back-and-forth direction (Y-axis direction); a second saddle 53 which is disposed on the first saddle 52 and can move freely in a horizontal side-to-side direction (X-axis direction); a spindle head 54 which is supported by the second saddle 53 and which can move freely in the vertical direction (Z-axis direction); a spindle 55 which is supported by the spindle head 54 so that its axis is parallel to the Z-axis and so as to be rotatable about its axis, and to the lower end portion of which a tool T is mounted; a table 56 which is disposed to the bed 51, and on which a workpiece W is placed; a Y-axis feed mechanism 57, X-axis feed mechanism 58 and Z-axis feed mechanism 59 for respectively moving the first saddle 52, second saddle 53 and spindle head 54 in their respective moving directions; a spindle motor 60 for rotating the spindle 55 about its axis; a coolant supply device 61 for supplying coolant to the contact portion of the tool T and the workpiece W; a control device 62 for controlling the operations of the feed mechanisms 57, 58 and 59, spindle motor 60 and coolant supply device 61; and an operation panel 63 connected to the control device 62.

The bed 51 has a configuration in which side walls 51 a, 51 b and 51 c are provided on the right, left and back sides thereof, respectively. The first saddle 52 is disposed on the upper portions of the right and left side walls 51 a and 51 b, and the table 56 is disposed to the back side wall 51 c. The operation panel 63 is configured with an input device 64 for inputting various signals to the control device 62 and a display device 65 for displaying the control state of the control device 62 and displaying images obtained from the actual CCD cameras 11, 12, 13 and 14, from the virtual image generating section 18, and from the sectional image generating section 26.

The control device 62 includes a program storage section 62 a in which a previously generated NC program is stored, and controls the feed mechanisms 57, 58 and 59, the spindle motor 60 and the coolant supply device 61 based on the NC program stored in the program storage section 62 a. Specifically, the control device 62 analyzes the NC program block by block, and in turn extracts operation commands relating to the moving positions and feed speed of the first saddle 52, second saddle 53 and spindle head 54, relating to the rotation speed of the spindle 55, and relating to the supply of coolant. Based on the extracted operation commands relating to the moving positions and feed speed of the first saddle 52, second saddle 53 and spindle head 54 and relating to the rotation speed of the spindle 55 and based on feedback signals from the feed mechanisms 57, 58 and 59 and spindle motor 60, the control device 62 controls the feed mechanisms 57, 58 and 59 and the spindle motor 60. Simultaneously, the control device 62 controls the coolant supply device 61 based on the extracted operation commands relating to the supply of coolant.

Further, the control device 62 controls the coolant supply device 61 (the supply and stop of coolant) based on input signals input from the input device 64 by an operator. And it is noted that the control device 62 transmits the extracted operation commands to the model data updating section 17, and transmits the signals relating to the coolant supply state (signal indicating that coolant is being supplied and signal indicating that coolant is not being supplied) to the display control section 23.

Next, the machining status monitoring apparatus 1 is explained. As described above, the machining status monitoring apparatus 1 has the actual CCD cameras 11, 12, 13 and 14 (first actual CCD camera 11, second actual CCD camera 12, third actual CCD camera 13 and fourth actual CCD camera 14), the camera parameter storage section 15, the model data storage section 16, the model data updating section 17, the virtual image generating section 18, the display control section 23 and the sectional image generating section 26. And a computer functions as the camera parameter storage section 15, the model data storage section 16, the model data updating section 17, the virtual image generating section 18, the display control section 23 and the sectional image generating section 26.

As shown in FIGS. 2 and 3, the actual CCD cameras 11, 12, 13 and 14 are arranged to surround the workpiece W on the table 56, and are configured so as to be able to image the workpiece W from four directions. Specifically, the first actual CCD camera 11 and the second actual CCD camera 12 are mounted at the front upper portion and rear upper portion of the left side wall 51 a of the bed 51 via brackets 11 a and 12 a, respectively. The third actual CCD camera 13 and the fourth actual CCD camera 14 are mounted at the front upper portion and rear upper portion of the right side wall 51 b of the bed 51 via brackets 13 a and 14 a, respectively. The actual CCD cameras 11, 12, 13 and 14 each image the tool T mounted to the spindle 55 and the workpiece W on the table 56 at a certain time interval, and in turn generate two-dimensional image data (actual image data) thereof, and output the generated two-dimensional image data to the display control section 23.

Examples of the actual image generated at this time are shown in FIG. 4. FIG. 4( a), FIG. 4( b), FIG. 4( c), and FIG. 4( d) show the actual image data generated by the fist actual CCD camera 11, the actual image data generated by the second actual CCD camera 12, the actual image data generated by the third actual CCD camera 13, and the actual image data generated by the fourth actual CCD camera 14, respectively. In these actual images, a part of the bed 51, a part of the spindle head 54, a part of the spindle 55 and a part of the table 56 are also included in addition to the tool T and the workpiece W.

In the camera parameter storage section 15, intrinsic and extrinsic parameters of the actual CCD cameras 11, 12, 13 and 14 are stored. The intrinsic parameters are characteristic parameters of each of the actual CCD cameras 11, 12, 13 and 14, and include, for example, a principal point coordinate, a scale factor, skewness of the two image axes and the like. The extrinsic parameters represent the positions and orientations of each of the actual CCD cameras 11, 12, 13 and 14 in the coordinate system of the machine tool 50. These parameters are previously calculated by a calibration process.

In the model data storage section 16, for example, previously generated data on a three-dimensional model (model data) of the entire machine tool 50 is stored. The model data of the entire machine tool 50 includes model data of the main components of the machine tool 50 such as the bed 51, the first saddle 52, the second saddle 53, the spindle head 54, the spindle 55 and the table 56, model data of the tool T mounted to the spindle 55, and model data of the workpiece W fixed on the table 56. And the model data of the components, tool T and workpiece W are related to one another.

The model data updating section 17 updates the model data of the entire machine tool 50 stored in the model data storage section 16 by carrying out a series of processes as shown in FIG. 5. This updating process is carried out synchronously with the actual operations of the first saddle 52, second saddle 53 and spindle head 54.

As shown in FIG. 5, first, the model data updating section 17 reads out the model data of the entire machine tool 50 stored in the model data storage section 16 (step S1), sets a counter n at 1 (step S2), and receives an operation command in the first block of a machining program from the control device 62 (step. S3).

Next, the model data updating section 17 recognizes the operation command which was received in step S3, and calculates interpolation points (step S4). For example, when the recognized operation command is a command to move the first saddle 52, the second saddle 53 and the spindle head 54, the model data updating section 17 sets a plurality of interpolation points on their respective moving paths between their respective movement start points and movement end points, and calculates the position of each interpolation point. By such interpolation, as described later, model data of the first saddle 52, second saddle 53 and spindle head 54 which gradually move from their respective movement start points toward their respective movement end points are generated.

Thereafter, the model data updating section 17 sets a counter m at 1 (step S5), and generates model data of the first saddle 52, second saddle 53 and spindle head 54 which are moved to the first point on their respective moving paths (step S6). At this time, if the model data of the tool T and the model data of the workpiece W partially overlap each other, the model data updating section 17 calculates the overlap area (cutting area), and generates the model data of the workpiece W so that this cutting area is removed therefrom. Thereafter, in step S7, the generated model data are stored in the model data storage section 16 and the model data therein are updated.

And, while updating the counter m, the processes of steps S6 and S7 are repeated until model data of the first saddle 52, second saddle 53 and spindle head 54 which are moved to the last point on their respective moving paths (that is, the moving positions according to the movement command) are generated and the model data in the model data storage section 16 are updated (steps S8 and S9).

Further, while updating the counter n, the processes of steps S3 to S9 are also carried out to all blocks in the machining program (steps S10 and S11). Thereafter, the series of processes are terminated.

The virtual image generating section 18 generates two-dimensional image data (virtual image data) of, for example, the tool T, workpiece W and a part of the table 56 by a computer process based on the parameters stored in the camera parameter storage section 15 and the model data updated by the model data updating section 17.

Specifically, the virtual image generating section 18 is configured to carry out a series of processes such as shown in FIG. 6. First, the virtual image generating section 18 reads out the parameters stored in the camera parameter storage section 15 (step S21), and then receives the model data updated by the model data updating section 17 (step S22).

Next, a three-dimensional space having the same coordinate system as the coordinate system of the machine tool 50 is virtually set (step S23). And, based on the read parameters and the received model data (the model data of the tool T, workpiece W and a part of the table 56 among the model data of the entire machine tool 50), in the set virtual three-dimensional space, three-dimensional models of the tool T, workpiece W and a part of the table 56 are arranged and virtual CCD cameras 19, 20, 21 and 22 (first virtual CCD camera 19, second virtual CCD camera 20, third virtual CCD camera 21 and fourth virtual CCD camera 22) are set and arranged as many as the actual CCD cameras 11, 12, 13 and 14 (step S24).

The fist virtual CCD camera 19 corresponds to the first actual CCD camera 11; the second virtual CCD camera 20 corresponds to the second actual CCD camera 12; the third virtual CCD camera 21 corresponds to the third actual CCD camera 13; and the fourth virtual CCD camera 22 corresponds to the fourth actual CCD camera 14. Since the virtual CCD cameras 19, 20, 21 and 22 are respectively arranged at the same positions and in the same orientations as the actual CCD cameras 11, 12, 13 and 14 based on the read extrinsic parameters, the view points of the virtual CCD cameras 19, 20, 21 and 22 match the view points of the actual CCD cameras 11, 12, 13 and 14, respectively. Since the intrinsic parameters of the virtual CCD cameras 19, 20, 21 and 22 are respectively set to be the same as the intrinsic parameters of the actual CCD cameras 11, 12, 13 and 14 based on the read intrinsic parameters, the conditions of the virtual CCD cameras 19, 20, 21 and 22 match the conditions of the actual CCD cameras 11, 12, 13 and 14, respectively.

Thereafter, the virtual image generating section 18 in turn generates two-dimensional image data which is assumed to be obtained when the tool T, workpiece W and a part of the table 56 which are represented by three-dimensional model are imaged at a certain time interval by the virtual CCD cameras 19, 20, 21 and 22, and transmits the generated two-dimensional image data to the display control section 23 (step S25).

Examples of the virtual image generated at this time are shown in FIG. 7. FIG. 7( a), FIG. 7( b), FIG. 7( c), and FIG. 7( d) show the virtual image data generated by the first virtual CCD camera 19, the virtual image data generated by the second virtual CCD camera 20, the virtual image data generated by the third virtual CCD camera 21, and the virtual image data generated by the fourth virtual CCD camera 22, respectively.

The display control section 23 is configured with a camera selection section 24 and a display-image switching section 25. The camera selection section 24 selects one actual CCD camera and one virtual CCD camera which are each able to capturing an image in which the distal end of the tool T is not hidden by the workpiece W, from the actual CCD cameras 11, 12, 13 and 14, and from the virtual CCD cameras 19, 20, 21 and 22, respectively, based on the virtual image data transmitted from the virtual image generating section 18.

Specifically, the camera selection section 24 is configured to carry out a series of processes as shown in FIG. 8. First, the camera selection section 24 receives the virtual image data transmitted from the virtual image generating section 18 (step S31), and then checks whether the distal end of the tool T is hidden by the workpiece W in all of the virtual images, based on the received virtual image data (step S32). It is noted that the determination whether the distal end of the tool T is hidden by the workpiece W can be made by referring to depth information in the Z-buffer in the virtual three-dimensional space, for example.

When determining that the distal end of the tool T is not hidden, the camera selection section 24 distinguishes the virtual image in which the distal end of the tool T is not hidden (step S33). When there is a plurality of the virtual images in which the distal end of the tool T is not hidden, any one of such virtual images is selected, for example, at random and distinguished. For example, in the case of the virtual images shown in FIG. 7, the image shown in FIG. 7( b) or 7(d) is distinguished.

Thereafter, the camera selection section 24 identifies the virtual CCD camera corresponding to the distinguished virtual image (step S34), and identifies the actual CCD camera corresponding to the identified virtual CCD camera (step S35). Next, the camera selection section 24 transmits a camera identification signal for distinguishing the identified actual CCD camera and the virtual image data distinguished in step S33 to the display-image switching section 25 (step S36).

On the other hand, in step S32, when determining that the distal end of the tool T is hidden in all of the virtual images, the camera selection section 24 transmits a sectional image generation signal to the sectional image generating section 26, and simultaneously transmits a sectional image display signal to the display-image switching section 25 (step S37). As an example of the case to which this is applied, the case where a groove Wa is formed on the workpiece W by machining as shown in FIG. 10 is provided.

The display-image switching section 25 displays on the display device 65 the actual image data output from any one of the actual CCD cameras 11, 12, 13 and 14, the virtual image data transmitted from the camera selection section 24, or the sectional image data transmitted from the sectional image generating section 26, and switches the image to be displayed between the actual image data, the virtual image data and the sectional image data.

Specifically, the display-image switching section 25 is configured to carry out a series of processes as shown in FIG. 9. First, the display-image switching section 25 receives the camera identification signal and virtual image data which are transmitted from the camera selection section 24, or the sectional image display signal (step S41), and receives a signal relating to the coolant supply state transmitted from the control device 62 (step S42).

Next, the display-image switching section 25 checks whether the sectional image display signal is received (step S43). When determining that the signal is received, the display-image switching section 25 receives the sectional image data transmitted from the sectional image generating section 26, and displays the received sectional image data on the display device 65 (step S44). As an example of the sectional image displayed at this time, the images shown in FIG. 11 are provided.

On the other hand, in step S43, when determining that the sectional image display signal is not received, the display-image switching section 25 checks whether coolant is being supplied to the contact portion of the tool T and the workpiece W, based on the signal relating to the coolant supply state received in step S42 (step S45). When determining coolant is not being supplied, the actual image data output from the actual CCD camera which is identified by the camera identification signal received in step S41 is displayed on the display device 65 (step S46). When determining coolant is being supplied, the virtual image data received in step S41 is displayed on the display device 65 (step S47). As an example of the actual image displayed at this time, the image shown in FIG. 4( b) or 4(d) is provided. As an example of the virtual image, the image shown in FIG. 7( b) or 7(d) is provided.

When receiving the sectional image generation signal transmitted from the camera selection section 24, the sectional image generating section 26 generates virtual two-dimensional image data as sectional image data by a computer process, based on the parameters stored in the camera parameter storage section 15 and the model data updated by the model data updating section 17, the virtual two-dimensional image data including, for example, a part of the table 56, the tool T, a sectional shape appearing when at least the workpiece W is cut along a predetermined cutting plane, and the shape of the workpiece W which is located behind the predetermined cutting plane. And the generated sectional image data is transmitted to the display-image switching section 25. The way of generating such sectional image is not particularly limited. For example, a sectional image can be generated in the same way as the virtual image data in the virtual image generating section 18.

The predetermined cutting plane is set so as to pass through at least the distal end of the tool (the intersection of the distal end surface of the tool T and the axis of the tool T (spindle 55)). As an example of the sectional image generated when, for example, the cutting plane passes through the distal end of the tool T and is parallel to the X-axis and the Z-axis, the sectional image shown in FIG. 11( a) is provided. As an example of the sectional image generated when, for example, the cutting plane passes through the distal end of the tool T and is perpendicular to the optical axis of the first actual CCD camera 11, the sectional image shown in FIG. 11( b) is provided. Besides, the cutting plane may be a plane which passes through the distal end of the tool T and is perpendicular to the optical axis of the actual CCD camera 12, 13 or 14.

When the cutting plane is set so as to be perpendicular to the optical axis of any one of the actual CCD cameras 11, 12, 13 and 14, it is preferred that the cutting plane is perpendicular to the optical axis of the CCD camera corresponding to the image data which has been displayed just before sectional image data is displayed on the display device 65 (when switching from actual image data or virtual image data to sectional image data). When configured so that the camera selection section 24 transmits the camera identification signal to the sectional image generating section 26 and the sectional image generating section 26 identifies the selected actual CCD camera 11, 12, 13 or 14 based on the camera identification signal, it is possible to distinguish the optical axis of the CCD camera corresponding to the image data which has been displayed just before sectional image data is displayed.

According to the machining status monitoring apparatus 1 of the present embodiment thus configured, first, the camera parameters of the actual CCD cameras 11, 12, 13 and 14 are stored in the camera parameter storage section 15 and the model data of the entire machine tool 50 is stored in the model data storage section 16.

When the feed mechanisms 57, 58 and 59 are driven by the control device 62, the model data of the entire machine tool 50 in the model data storage section 16 is updated by the model data updating section 17 synchronically with the actual operations of the first saddle 52, second saddle 53 and spindle head 54, based on the operation command obtained from the control device 62. It is noted that, in the machine tool 50, coolant is supplied to the contact portion of the tool T and the workpiece W depending on the contents of machining during the machining of the workpiece W.

The tool T and the workpiece W are imaged by the actual CCD cameras 11, 12, 13 and 14 and actual image data thereof are generated. Simultaneously, by the virtual image generating section 18, virtual image data of the tool T, workpiece W and a part of the table 56 are generated correspondingly to each of the virtual CCD cameras 19, 20, 21 and 22, based on the parameters in the camera parameter storage section 15 and the model data updated by the model data updating section 17.

When virtual image data are generated, the camera selection section 24 selects one actual CCD camera and one virtual CCD camera which are each able to capture an actual image or a virtual image in which the distal end of the tool T is not hidden by the workpiece W, based on the generated virtual image data. Alternatively, the determination is made that the distal end of the tool T is hidden in all of the virtual images and a sectional image generation signal is generated.

When a sectional image generation signal is generated, the sectional image generating section 26 generates sectional image data including a part of the table 56, the tool T, a sectional shape appearing when at least the workpiece W is cut, and the shape of the workpiece W which is located behind the cutting plane, based on the parameters in the camera parameter storage section 15 and the model data updated by the model data updating section 17.

Under the control of the display-image switching section 25, the actual image data which is generated by the actual CCD camera selected by the camera selection section 24 is displayed when coolant is not being supplied, and the virtual image data which is generated by the virtual CCD camera selected by the camera selection section 24 is displayed when coolant is being supplied. When sectional image data is generated by the sectional image generating section 26, then such sectional image data is displayed.

Thus, according to the machining status monitoring apparatus 1 of the present embodiment, it is configured so that the virtual CCD camera which generated the virtual two-dimensional image data in which the distal end of the tool T is not hidden by the workpiece W is identified based on the virtual two-dimensional image data generated by imaging the tool T and the workpiece W from different view points by means of a plurality of the virtual CCD cameras 19, 20, 21 and 22 and the actual two-dimensional image data generated by the actual CCD camera corresponding to the identified virtual CCD camera is displayed on the display device 65. Therefore, an actual image in which the distal end of the tool T is not hidden by the workpiece W can be always displayed when displaying an actual image. Thereby, the operator can always visually recognize the machining status of the workpiece W through the image displayed on the display device 65, wherein it is possible to sufficiently monitor the machining status.

If it is configured so that all of the actual two-dimensional image data generated by the actual CCD cameras 11, 12, 13 and 14 are displayed on the display device 65, a heavy load is applied to the computer, which has a bad influence upon other processes. However, in the present embodiment, since it is configured so that only the actual two-dimensional image data generated by any one of the actual CCD cameras 11, 12, 13 and 14 is displayed, it is possible to reduce the load.

When the distal end of the tool T is hidden by the workpiece W in all of the virtual two-dimensional images, the sectional image data generated by the sectional image generating section 26 is displayed on the display device 65. Therefore, even if machining in which the distal end of the tool T is hidden by the workpiece W, such as hole machining or groove machining, is performed, the operator can monitor the machining status of the workpiece W through the displayed images.

Further, when setting a plane which passes through the distal end of the tool T and is perpendicular to the optical axis of any one of the actual CCD cameras 11, 12, 13 and 14 as a cutting plane for generating sectional image data, the sectional image when viewing the tool T and the workpiece W from the same direction as any one of the actual and virtual CCD cameras 11, 12, 13, 14, 19, 20, 21 and 22 can be displayed. Therefore, it is possible to prevent the operator from having the difficulty of recognizing the direction from which the tool T and the workpiece W are viewed because of the change of view direction.

Further, since the operator can visually recognize the machining status of the workpiece W through the virtual image when coolant is being supplied to the contact portion of the tool T and the workpiece W, and through the actual image when coolant is not being supplied, the operator can monitor the machining status of the workpiece W even when coolant is being supplied.

Thus, one embodiment of the present invention has been described. However, specific modes in which the present invention is realized are not limited thereto.

For example, the cutting plane for cutting the workpiece W is not limited to the above-described cutting plane and it may be a plane which passes through the distal end of the tool T and is parallel to the Y-axis and the Z-axis, for example. Alternatively, when the tool T moves linearly, it is may be a plane which passes through the axis of the tool T and is parallel to the moving direction of the tool T. Further, when the tool T moves in a circle, it may be a plane which passes through the axis of the tool T and the center of the circle. It is noted that the moving direction of the tool T is recognized by the sectional image generating section 26 reading ahead the NC program, or recognized based on the predicted moving position of the tool T which is obtained from the control device 62, for example.

In the above embodiment, it is configured so that the camera selection section 24 distinguishes one virtual image in which the distal end of the tool T is not hidden in step S33. However, it can be configured so that all of the virtual images in which the tool T is not hidden are distinguished, or so that some of the virtual images in which the tool T is not hidden are distinguished. When thus configured, a plurality of the actual images or virtual images in which the distal end of the tool T is not hidden can be displayed on the display device 65.

Further, in the above embodiment, the actual CCD cameras 11, 12, 13 and 14 image the tool T and the workpiece W and the virtual image generating section 18 generates virtual image data of the tool T, workpiece W and a part of the table 56. However, since a jig is usually used when fixing the workpiece W on the table 56, it may be configured so that the actual CCD cameras 11, 12, 13 and 14 image the tool T, the workpiece W and the jig and the virtual image generating section 18 generates virtual image data of the tool T, workpiece W, a part of the table 56 and the jig. In this case, an actual image or virtual image in which the distal end of the tool T is hidden neither by the workpiece W nor by the jig is displayed.

Moreover, the machine tool 50 provided with the machining status monitoring apparatus 1 is not limited and any machine tool 50 is acceptable. For example, instead of the machining center in the above embodiment, the machining status monitoring apparatus 1 may be provided on a lathe or the like. In the case of a lathe, the cutting plane for generating sectional image data is preferably a plane passing through the distal end (edge portion) of the tool T and the axis of a spindle 70 (chuck 71) as shown in FIG. 12. In FIG. 12, the reference number 71 designates a chuck mounted to the distal end of the spindle 70 for holding the workpiece W; the reference number 71 a designates a gripping jaw of the chuck 71; and the reference number 72 designates a tool rest for holding the tool T.

REFERENCE SIGNS LIST

-   -   1 machining status monitoring apparatus 1     -   11, 12, 13, 14 actual CCD camera     -   15 camera parameter storage section     -   16 model data storage section     -   17 model data updating section     -   18 virtual image generating section     -   19, 20, 21, 22 virtual CCD camera     -   23 display control section     -   24 camera selection section     -   25 display-image switching section     -   26 sectional image generating section     -   50 machining tool     -   55 spindle     -   56 table     -   61 coolant supply device     -   W workpiece     -   T tool

Citation List Patent Literature

Japanese Unexamined Patent Application Publication No. 2005-190102 

1. A machining status monitoring method for, in a machine tool in which one or both of tool holding means for holding a tool and workpiece holding means for holding a workpiece are operated based on operation commands, monitoring the machining status with actual two-dimensional image data displayed on display means, the actual two-dimensional image data generated by at least one of a plurality of actual imaging means, disposed in the machine tool, for imaging the tool and workpiece, or the tool, workpiece and workpiece holding means at a certain time interval from different view points, and in turn generating actual two-dimensional image data thereof, wherein based on the operation commands and data on three-dimensional models of the holding means, tool and workpiece, model data of the holding means, tool and workpiece when one or both of the holding means are operated according to the operation command are generated and the model data thereof are updated, simultaneously virtual two-dimensional image data of the tool and workpiece, or virtual two-dimensional image data of the tool, workpiece and workpiece holding means, the virtual two-dimensional image data which is assumed to be obtained when a three-dimensional space is virtually set; in this virtual three-dimensional space, the three-dimensional models of the tool and workpiece, or the three-dimensional models of the tool, workpiece and workpiece holding means are arranged and imaging means having the same condition as that of the actual imaging means are virtually set and arranged as many as the actual imagining means; and the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the virtual imaging means from the same view points as those of the actual imaging means, are in turn generated based on the updated model data, and based on the generated virtual two-dimensional image data, at least one is selected from the virtual imaging means corresponding to, among a plurality of the virtual two-dimensional images, the virtual two-dimensional images in which the distal end of the tool is not hidden by the workpiece or the workpiece holding means and the actual two-dimensional image data generated by the actual imaging means corresponding to the selected virtual imaging means, is displayed on the display means.
 2. A machining status monitoring apparatus provided on a machine tool having tool holding means for holding a tool, workpiece holding means for holding a workpiece, drive means for operating one or both of the holding means, control means for controlling the operation of the drive means based on the operation commands relating to one or both of the holding means, and display means for displaying image data, the machining status monitoring apparatus comprising: a plurality of actual imaging means for imaging the tool and workpiece, or the tool, workpiece and workpiece holding means at a certain time interval from different view points, and in turn generating actual two-dimensional image data thereof; model data updating means for, after receiving an operation command from the control means, based on the received operation command and data on three-dimensional models of the holding means, tool and workpiece, generating model data of the holding means, tool and workpiece which are in a state in which one or both of the holding means were operated according to the operation command, and updating the model data thereof; virtual image generating means for generating virtual two-dimensional image data of the tool and workpiece, or virtual two-dimensional image data of the tool, workpiece and workpiece holding means, based on the model data updated by the model data updating means, the virtual image generating means in which virtual two-dimensional image data which are assumed to be obtained when a three-dimensional space is virtually set; in this virtual three-dimensional space, the three-dimensional models of the tool and workpiece, or the three-dimensional models of the tool, workpiece and workpiece holding means, are arranged and imaging means having the same condition as that of the actual imaging means are virtually set and arranged as many as the actual imagining means; and the tool and workpiece, or the tool, workpiece and workpiece holding means are imaged at a certain time interval by the virtual imaging means from the same view points as those of the actual imaging means, are generated in turn; and display control means for, based on the virtual two-dimensional image data generated by the virtual image generating means, selecting at least one from the virtual imaging means corresponding to, among a plurality of the virtual two-dimensional images, the virtual two-dimensional images in which the distal end of the tool is not hidden by the workpiece or the workpiece holding means, and displaying the actual two-dimensional image data generated by the actual imaging means corresponding to the selected virtual imaging means on the display means.
 3. The machining status monitoring apparatus according to claim 2, wherein the machining status monitoring apparatus has sectional image generating means for generating sectional image data including the tool and a sectional shape appearing when at least the workpiece is cut along a plane passing through the distal end of the tool based on the model data updated by the model data updating means, and the display control means is configured to, based on the virtual two-dimensional image data generated by the virtual image generating means, check whether the distal end of the tool is hidden by the workpiece in all of the virtual two-dimensional images, and display the sectional image data generated by the sectional image generating means on the display means when determining that the distal end of the tool is hidden in all of the virtual two-dimensional images.
 4. The machining status monitoring apparatus according to claim 3, wherein the sectional image generating means is configured to set a plane which passes through the distal end of the tool and is perpendicular to the optical axis of any one of the actual imaging means as a cutting plane in generating the sectional image data.
 5. The machining status monitoring apparatus according to claim 3, wherein in a case where the machine tool is a lathe and the workpiece holding means is a spindle, the sectional image generating means is configured to set a plane passing through the distal end of the tool and the axis of a spindle as a cutting plane in generating the sectional image data. 